PCB Piezotronics TORKDISC 5302D-02A/TCS-0X User manual

Model 5302D-02A/TCS-0X
TORKDISC® Rotary Torque Sensing System
Installation and Operating Manual
For assistance with the operation of this product,
contact PCB Piezotronics, Inc.
Toll-free: 800-828-8840
24-hour SensorLine: 716-684-0001
Fax: [phone]
E-mail: [email protected]
Web: www.pcb.com

The information contained in this document supersedes all similar information that
may be found elsewhere in this manual.
Service –Due to the sophisticated
nature of the sensors and associated
instrumentation provided by PCB
Piezotronics, user servicing or repair is
not recommended and, if attempted,
may void the factory warranty. Routine
maintenance, such as the cleaning of
electrical connectors, housings, and
mounting surfaces with solutions and
techniques that will not harm the
physical material of construction, is
acceptable. Caution should be observed
to ensure that liquids are not permitted
to migrate into devices that are not
hermetically sealed. Such devices
should only be wiped with a dampened
cloth and never submerged or have
liquids poured upon them.
Repair –In the event that equipment
becomes damaged or ceases to
operate, arrangements should be made
to return the equipment to PCB
Piezotronics for repair. User servicing or
repair is not recommended and, if
attempted, may void the factory
warranty.
Calibration –Routine calibration of
sensors and associated instrumentation
is recommended as this helps build
confidence in measurement accuracy
and acquired data. Equipment
calibration cycles are typically
established by the users own quality
regimen. When in doubt about a
calibration cycle, a good “rule of thumb”
is to recalibrate on an annual basis. It is
also good practice to recalibrate after
exposure to any severe temperature
extreme, shock, load, or other
environmental influence, or prior to any
critical test.
PCB Piezotronics maintains an ISO-
9001 certified metrology laboratory and
offers calibration services, which are
accredited by A2LA to ISO/IEC 17025,
with full traceability to SI through
N.I.S.T. In addition to the normally
supplied calibration, special testing is
also available, such as: sensitivity at
elevated or cryogenic temperatures,
phase response, extended high or low
frequency response, extended range,
leak testing, hydrostatic pressure
testing, and others. For information on
standard recalibration services or
special testing, contact your local PCB
Piezotronics distributor, sales
representative, or factory customer
service representative.
Returning Equipment –Following
these procedures will ensure that your
returned materials are handled in the
most expedient manner. Before
returning any equipment to PCB
Piezotronics, contact your local
distributor, sales representative, or
factory customer service representative
to obtain a Return Warranty, Service,
Repair, and Return Policies and
Instructions Materials Authorization
(RMA) Number. This RMA number
should be clearly marked on the outside
of all package(s) and on the packing
Service, Repair, and Return
Policies and Instructions

list(s) accompanying the shipment. A
detailed account of the nature of the
problem(s) being experienced with the
equipment should also be included
inside the package(s) containing any
returned materials.
A Purchase Order, included with the
returned materials, will expedite the
turn-around of serviced equipment. It is
recommended to include authorization
on the Purchase Order for PCB to
proceed with any repairs, as long as
they do not exceed 50% of the
replacement cost of the returned
item(s). PCB will provide a price
quotation or replacement
recommendation for any item whose
repair costs would exceed 50% of
replacement cost, or any item that is not
economically feasible to repair. For
routine calibration services, the
Purchase Order should include
authorization to proceed and return at
current pricing, which can be obtained
from a factory customer service
representative.
Contact Information –International
customers should direct all inquiries to
their local distributor or sales office. A
complete list of distributors and offices
can be found at www.pcb.com.
Customers within the United States may
contact their local sales representative
or a factory customer service
representative. A complete list of sales
representatives can be found at
www.pcb.com. Toll-free telephone
numbers for a factory customer service
representative, in the division
responsible for this product, can be
found on the title page at the front of this
manual. Our ship to address and
general contact numbers are:
PCB Piezotronics, Inc.
3425 Walden Ave.
Depew, NY14043 USA
Toll-free: [phone]
24-hour SensorLineSM: [phone]
Website: www.pcb.com
E-mail: [email protected]

PCB工业监视和测量设备 - 中国RoHS2公布表
PCB Industrial Monitoring and Measuring Equipment - China RoHS 2 Disclosure Table
部件名称
有害物质
铅(Pb)
汞
(Hg)
镉
(Cd)
六价铬(Cr(VI))
多溴联苯 (PBB)
多溴二苯醚(PBDE)
住房
O
O
O
O
O
O
PCB板
X
O
O
O
O
O
电气连接器
O
O
O
O
O
O
压电晶体
X
O
O
O
O
O
环氧
O
O
O
O
O
O
铁氟龙
O
O
O
O
O
O
电子
O
O
O
O
O
O
厚膜基板
O
O
X
O
O
O
电线
O
O
O
O
O
O
电缆
X
O
O
O
O
O
塑料
O
O
O
O
O
O
焊接
X
O
O
O
O
O
铜合金/黄铜
X
O
O
O
O
O
本表格依据 SJ/T 11364 的规定编制。
O：表示该有害物质在该部件所有均质材料中的含量均在 GB/T 26572 规定的限量要求以下。
X：表示该有害物质至少在该部件的某一均质材料中的含量超出 GB/T 26572 规定的限量要求。
铅是欧洲RoHS指令2011/65/ EU附件三和附件四目前由于允许的豁免。
CHINA RoHS COMPLIANCE

DOCUMENT NUMBER: 21354
DOCUMENT REVISION: D
ECN: 46162
Component Name
Hazardous Substances
Lead
(Pb)
Mercury
(Hg)
Cadmium
(Cd)
Chromium VI
Compounds
(Cr(VI))
Polybrominated
Biphenyls
(PBB)
Polybrominated
Diphenyl
Ethers (PBDE)
Housing
O
O
O
O
O
O
PCB Board
X
O
O
O
O
O
Electrical
Connectors
O
O
O
O
O
O
Piezoelectric
Crystals
X
O
O
O
O
O
Epoxy
O
O
O
O
O
O
Teflon
O
O
O
O
O
O
Electronics
O
O
O
O
O
O
Thick Film
Substrate
O
O
X
O
O
O
Wires
O
O
O
O
O
O
Cables
X
O
O
O
O
O
Plastic
O
O
O
O
O
O
Solder
X
O
O
O
O
O
Copper Alloy/Brass
X
O
O
O
O
O
This table is prepared in accordance with the provisions of SJ/T 11364.
O: Indicates that said hazardous substance contained in all of the homogeneous materials for this part is below the limit
requirement of GB/T 26572.
X: Indicates that said hazardous substance contained in at least one of the homogeneous materials for this part is above
the limit requirement of GB/T 26572.
Lead is present due to allowed exemption in Annex III or Annex IV of the European RoHS Directive 2011/65/EU.

PCB Load & Torque Toll-Free in USA 866-684-7107 716-684-0001 www.pcb.com
16-BIT TORKDISCROTARY TORQUE SENSOR SYSTEM OPERATION MANUAL
1
TABLE OF CONTENTS
GENERAL GUIDELINES...........................................................................................................2
WARNING SYMBOLS AND TERMS.........................................................................................2
1.0 INTRODUCTION..................................................................................................................3
2.0 SAFETY PRECAUTIONS....................................................................................................3
3.0 OVERVIEW..........................................................................................................................3
3.1 Supplied Components.......................................................................................................................3
3.2 Dimensions .......................................................................................................................................3
3.3 Theory of Operation..........................................................................................................................5
4.0 ELECTRICAL OPERATION ................................................................................................6
4.1 Receiver Box – Front Panel..............................................................................................................6
4.2 Receiver Box – Back Panel ..............................................................................................................6
4.3 Receiver Box – I/O Connector Pinouts.............................................................................................7
4.4 Receiver Box – Adjustment Controls................................................................................................8
4.4.1 System Gain Range.................................................................................................................9
4.4.2 Zero/Additional Offset..........................................................................................................10
4.4.3 AC Gain................................................................................................................................10
4.4.4 Low & High Pass Filters.......................................................................................................11
4.4.4.1 Low Pass Filter.......................................................................................11
4.4.4.2 Composite Low Pass Filter.....................................................................12
4.4.4.3 Composite High Pass Filter ....................................................................13
5.0 MECHANICAL INSTALLATION........................................................................................14
5.1 TORKDISC  Installation................................................................................................................14
5.2 Mating Adaptors..............................................................................................................................16
6.0 SYSTEM OPERATION ......................................................................................................17
6.1 System Tuning................................................................................................................................17
7.0 CALIBRATION...................................................................................................................17
7.1 Analog Output – Voltage.................................................................................................................18
7.2 Frequency Output ...........................................................................................................................18
8.0 TROUBLESHOOTING.......................................................................................................19
9.0 CALIBRATION / REPAIR SERVICES...............................................................................20
9.1 RMA / Purchase Order....................................................................................................................20
10.0 WARRANTY ....................................................................................................................20

PCB Load & Torque Toll-Free in USA 866-684-7107 716-684-0001 www.pcb.com
16-BIT TORKDISCROTARY TORQUE SENSOR SYSTEM OPERATION MANUAL
2
GENERAL GUIDELINES
Operators should read this manual and become thoroughly familiar with its contents before attempting to
operate the 16-bit TORKDISCrotary torque sensor system. Following the safety considerations and
operation instructions outlined in this manual will minimize the possibility of accidents or injury. Although the
procedures covered in this manual have proven safe in use, PCB Load & Torque assumes no responsibility for
personal injury or damage to equipment resulting from their application. After reading this manual, personnel
should review all instructions concerning safety procedures provided at the installation location. It is not
possible to cover all safety considerations in this manual; therefore, always be alert and work safely. Only
qualified system operators should perform the procedures covered in this manual.
WARNING SYMBOLS AND TERMS
This symbol on the unit indicates that the user should refer to the operating instructions located
in the manual.
This symbol on the unit indicates that high voltage may be present. Use standard safety
precautions to avoid personal contact with this voltage.
This system indicates safety, earth ground.
Indicates a potentially dangerous situation, which can lead to minor or moderate injury or property damage. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a potentially dangerous situation, which can lead to severe personal injury or death. Always read the
associated information very carefully before performing the indicated procedure.
WARNING
Indicates an imminently dangerous situation, which can lead to severe personal injury or death.
DANGER

PCB Load & Torque Toll-Free in USA 866-684-7107 716-684-0001 www.pcb.com
16-BIT TORKDISCROTARY TORQUE SENSOR SYSTEM OPERATION MANUAL
3
1.0 INTRODUCTION
The TORKDISCis ideally designed to measure in-line rotating
shaft torque and incorporates a unique digital telemetry system to
transmit sensor excitation and output between the rotor and stator
portion of the system,
This manual provides instructions for installation, calibration,
operation, and troubleshooting.
2.0 SAFETY PRECAUTIONS
3.0 OVERVIEW
The TORKDISCproduct is a DC powered instrument and includes an external AC/DC power supply. The
transmitter potted into the disc is inductively powered so it does not require any batteries or maintenance. This
manual covers three series of TORKDISCranging in full-scale capacities from 500 to 100k in-lbf.
3.1 Supplied Components
The TORKDISCrotary torque sensor system comes supplied with the following equipment:
•TORKDISCrotor and stator/antenna assemblies.
•Receiver box with DB25 female connector w/mating connector
•Power supply with power cord
•24 foot long BNC plug to TNC plug cable
3.2 Dimensions
This section gives some general dimensions for common TORKDISCassembly models. Reference the
individual model’s outline drawing for extra details or special versions.
Figure 1 – TORKDISCLoading &
Components
Personal injury to the operator, as well as, damage to the equipment may result if the TORKDISCis operated at
speeds higher than the maximum rated speed, or with loads greater than the overload capacity listed on the
specification sheet. The operator should be protected from rotating parts by using safety shield guards. When in
doubt about speed ratings or torque capacity, consult the Load & Torque Division of PCB Piezotronics.
CAUTION
Stator/Antenna
Rotor
CW +

PCB Load & Torque Toll-Free in USA 866-684-7107 716-684-0001 www.pcb.com
16-BIT TORKDISCROTARY TORQUE SENSOR SYSTEM OPERATION MANUAL
4
NOTE: See the outline drawing for the respective series for additional dimensions and bolt circle details.
Figure 2 - Dimensions
Table 1
-
Dimension Values
Dimensions
(see Figure 2)
Series Number
5302
5308
5302
500 – 5k in-lbf 2.4k – 30k in-lbf 50k – 100k in-lbf
(in) (mm) (in) (mm) (in) (mm)
1
9.00 228.6 10.50 266.7 12.45 316.3
2
10.92 277.5 12.28 311.9 14.20 360.6
3 ∅5.99 ∅152.0 ∅7.49 ∅190.1 ∅9.49 ∅240.9
4
7.00 177.8 7.00 177.8 7.00 177.8
5
2.49 63.2 2.49 63.2 2.49 63.2
6
6.12 155.4 6.12 155.4 6.12 155.4
7
7.02 178.2 7.62 193.4 8.58 217.8
8
1.28 32.5 1.28 32.5 1.28 32.5
9
1.55 39.4 1.55 39.4 1.55 39.4
10
0.31 7.9 0.31 7.9 0.31 7.9
11
R0.17 R4.2 R0.17 R4.2 R0.17 R4.2
12 8X ∅0.406
THRU ON
∅5.000
8X ∅10.31
THRU ON
∅127.00
8X ∅0.531
THRU ON
∅6.500
8X
∅13.49THRU
ON ∅165.10
16X ∅0.531
THRU ON
∅8.500
16X ∅13.49
THRU ON
∅215.90
13 8X 3/8”-24
THRU ON
∅3.000
8X 3/8”-24
THRU ON
∅76.25
8X 5/8”-11
THRU ON
∅3.750
8X 5/8”-11
THRU ON
∅95.25
12X 5/8”-11
THRU ON
∅6.000
12X 5/8”-11
THRU ON
∅152.40
14 22.5°22.5°22.5°22.5°22.5°22.5°
15 22.5°
22.5° 28° 28° 25°* 25°*
*20°between holes
4
1
11
9
3
2
6
10
15
15
14
8
5
7
13
12

PCB Load & Torque Toll-Free in USA 866-684-7107 716-684-0001 www.pcb.com
16-BIT TORKDISCROTARY TORQUE SENSOR SYSTEM OPERATION MANUAL
5
3.3 Theory of Operation
The TORKDISCsystem utilizes a unique digital data transmission technique. A radio frequency signal
generated within the receiver box is inductively coupled from the pick-up antenna to the transmitting antenna
and rectified to provide DC voltages to operate the rotating TORKDISCtransmitter. The transmitter has been
configured for a full-scale input of ±1.5mV/V. The rotating circuitry provides excitation for the strain gage
bridge, amplifies, and filters its output. The resulting signal is presented to an analog to digital converter that
samples it and converts it to a noise immune digital code. To provide up to a 8.5kHz measurement bandwidth
without creating aliasing errors, the A-to-D converter samples at a rate in excess of 26,000 samples per second.
Data bits are transmitted off the rotor in this digitally encoded form. In this manner, they are not subject to
noise degradation or "per rev" effects.
The digital data bits are recovered in the receiver box where they are re-converted to an analog signal. This
signal is used to generate the standard voltage output, consult the factory for optional frequency system outputs.
The specified bandwidth represents the electronic capability of the TORKDISCSystem only and does not
reflect actual installed system performance and the influence of sensor and system mechanics. It is advisable
that the customer model the entire drive line with the sensor installed and /or conduct an in-situ torsional
vibration analysis to determine the measurement bandwidth.
The calibration of the TORKDISCsystem is easy to accomplish and is extremely stable over time. The
product is equipped with a remotely activated shunt calibration feature that can be controlled from the front
panel of the receiver box. This allows the user to check calibration at any time during system operation. When
the shunt calibration feature is invoked, a precision resistor is switched across one leg of the Wheatstone bridge,
producing a positive shift in the receiver’s output.